Adjustable pouch forming, filling and sealing apparatus and methods

ABSTRACT

An adjustable pouch machine comprises a vertical sealer module forms transverse seals between two plies of a pouch web to partially define a plurality of pouches. Rollers selectively tension and relax the web on the vertically oriented wheel, allowing them to drop away from heated lands on emergency and cycle stops. A filler wheel has a plurality of adjustable gripper units mounted directly thereon for transporting independent separate pouches cut from the pouch web. An adjustable knife is selectively provided with changeable knife hub sets to handle a variety of pouch sizes where a filler wheel alternately first fills and seals pouches in a train. Gear linkage accommodates variation in distance between hubs of different sets. Various embodiments, apparatus and methods are described.

PRIORITY CLAIM

Applicant claims the benefit of the filing date of the U.S. provisionalpatent application Ser. No. 60/763,940 by the same title, filed on Jan.31, 2006.

FIELD OF THE INVENTION

This invention relates to pouch forming, pouch filling and pouchsealing. More particularly, this invention relates to apparatus andmethods for performing these operations for a wide range of pouch sizesin an adjustable pouch machine.

BACKGROUND OF THE INVENTION

In the past, pouches have been formed, filled and sealed in a variety ofways. Some prior devices operated on an intermittent basis, which is notgenerally conducive to efficiency where pouches must be formed, filledand sealed at higher rates than intermittent motion machines caneffectively produce.

in one prior continuous operation, such as illustrated in U.S. Pat. No.3,821,873, expressly incorporated herein by reference as if fully setout herein, pouches are formed by folding a pouch web lengthwise,creating transverse seals across the folded web to form a series ofpouches in a pouch train by running the folded web around a horizontallydisposed wheel where spaced heated sealing lands seal the web together,transporting the web train around a filler wheel, filling pouches as thetrain is moved around the filler, sealing the open pouch tops, thencutting pouches from the train at pouch edges defined by the cut linesalong the transverse seal areas. Such pouch forming, filling and sealingequipment is very efficient and operates at relatively high speedscompared to an intermittent pouch operation.

While such, equipment works well for pouches of a given pitch or width,use of the same equipment to form, fill and seal pouches ofsignificantly different widths requires a significant number of majorchange parts. For example, the entire web sealer wheel and entire fillerwheel structure must typically be changed out.

See, for example, the pouch machine disclosed in U.S. Pat. No.5,502,951, which is expressly incorporated herein by reference. Thatmachine handles a degree of pouch width variations by use of coordinatedsealer wheel and filler wheel change parts, whose drives aremechanically linked in cooperation. The number of pouch stations on thesealer must be associated in whole number relation to those on thefiller wheel about which the pouch train is engaged on vacuum lands.

In this application, the phrase “pouch width” is used to refer to thatdistance from one vertical pouch edge to the opposite vertical edge ofthe same pouch when the pouches are oriented with their mouths abovetheir folded bottom and the edges extend between the mouths and thebottom on both sides of the pouch. The “width” is typically extended inthe same direction the pouches move through the pouch forming sealersand pouch fillers.

The term “pitch” generally refers to the distance from one point of apouch to the identical point on an immediately preceding or succeedingpouch. Thus, pouch “pitch” might be, for example, that distance from aleading edge of one pouch to the same leading edge of an immediatelyfollowing pouch, however it is transported.

The phrase “pitch line” is used to identify the line or path thatpouches follow through the process.

As used herein, the terms “wheel” and “filler wheel” refer to anywheel-like or annular structure operable as described herein andincluding but not limited to a solid, circular disk, or annulus or ring,or other shaped configuration or structure capable of carrying thegripper units or pouch supporting lands as described herein about orthrough a curved or circular pouch pitch line or path for filling, andthrough a variety of stages or sectors as described herein.

In other prior U.S. Pat. Nos. 6,657,165 and 6,917,014, a horizontallyoriented sealer wheel is provided with heated sealing lands which haveslight radial adjustments to permit some adjustment between the paralleltransverse seals, but the adjustment provided is insufficient to providethe extent of pouch width size adjustment now desired in the industry,such as for pouches ranging from about 2.5 inches to about 5.5 inches inmajor width. Major change parts are required and the changeoverprocedures are time consuming, but necessary for a pouch operation withthe capacity to handle a wide range of pouch widths.

It is now desired in the industry to have equipment capable ofcontinuously forming, filling and sealing pouches having widths varyingin different pouch runs from about 2.5 inches width (seal-to-seal) toabout 5.5 inches width, and at high speeds up to about 500 pouches perminute on the sealer wheel. And at the filler wheel, depending on thepitch or number of stations around the circumference of a given fillerwheel, throughput speeds of up to 3750 inches per minute (at the pouchpath) are desired. While prior apparatus has provided some degree ofadjustability, for slighter pouch width variations than noted above,there is no known equipment capable of handling pouches at high speedand in the now desired width range without significant changeover parts,time and cost.

In another aspect of such pouch operations, consideration must be givento the handling of the pouch web on the sealer wheel.

In the typical prior operation, the folded web is disposed horizontallyaround a horizontally disposed sealer wheel on a vertical axis andhaving a plurality of spaced heated sealing lands against which the webis tensioned. Such wheels and lands are constructed so that traverseseals are created across the web plies from the bottom web fold line tothe open top edges of the plies. Such sealer wheels work well incontinuous operation but accommodation must be made for operational or“cycle stops” where the process and the web must be stopped momentarily,or for an extensive time. Heat from the lands transfers into the stoppedweb at the seals and the seal propagation in the web at the seals canunduly widen the seals or the excessive heat transfer due to extendeddwell time can even burn through the web, breaking the web on the wheelor otherwise rendering pouches on the wheel unusable on system start. Inthe past, such sealers have sometimes been referred to as “verticalsealers”, but this refers to the orientation of the seal in the pouchweb sides when the folded web is vertically oriented, and not to theorientation of the sealer wheel itself, which is typically horizontal,rotating about a vertical axis.

It is thus desirable to provide a continuous web sealer where,nevertheless, undue heat transfer and seal propagation on cycle stops iseliminated.

In another typical system for forming, filling and sealing pouches, thepouches are cut apart from the pouch train before filling. Suchapparatus is clearly described and shown in U.S. Pat. No. 4,956,964which is expressly incorporated herein by reference as if fullyexpressly set forth herein. These pouches are delivered to a pair ofpouch gripping jaws carried on a carrier chain. The leading edge or sealof the pouch is gripped by a leading gripper jaw of the jaw pair, whilethe trailing pouch edge or seal is gripped by a trailing gripper jaw,generally at a distance below the open pouch mouth which is directedupwardly. These jaws are relatively movable with respect to each otherto allow the pouch to be opened and filled. The individual pouches arethen sealed and discharged.

In this system, the gripper jaws are carried by chains drawn aroundrespective sprockets. These require maintenance and are somewhat noisycompared to systems where the uncut pouch train engages with fillerwheel lands and is filled about a filler wheel which had no chains,sprockets or grippers.

It will thus be appreciated that systems for handling a wide range ofpouch widths or pitch in the now desired range of about 2.5 to 5.5inches and at effective pouch machine speeds up to about 3750 inches perminute must take into account numerous pouch handling functions offilling, sealing and cutting. Sealing apparatus must be capable ofproducing final pouch seals in the pouch web for the extremes of pouchsizes and provision must be made to eliminate seal propagation, burnthrough or heat caused pouch destruction during cycle stops, similar tothose issues in the pouch forming process. Moreover, provisions must bemade to accommodate the varied pouch width extremes on the filler wheel,and provisions must be made for accurately cutting pouch after pouchfrom either the formed or filled web within the seal areas. All thismust be accomplished on a continuous basis with as little pouchrejection as possible, for the noted wide range of possible pouchwidths. The cost of obtaining a plurality of machines, each to handle asingle pouch size, even if slightly variable by adjustment within a verynarrow range, is prohibitively expensive, and at the least takes up toomuch production floor space.

In another consideration of pouching operations, there is a concern ofcleanliness resulting from stray product. Frequently, the product loadedinto the pouches is a powder, fine particles or a frangible product.Stray product contaminates pouching apparatus and requires frequent washdown or cleaning. Where the pouch apparatus is fully integrated,cleaning of the filling area where pouches are filled and most likely tohave stray product involves or intrudes into other components of theequipment, whether cleaning is needed there or not.

It has been one objective of the invention to provide an improved pouchforming, filling and sealing apparatus and methods capable of handling awide range of pouch widths at high speed.

A further objective of one embodiment of the invention has been toprovide apparatus and methods for forming, filling and sealing pouchesin a wide range of pouch widths while requiring only minimal, if any,change parts.

A further objective of the invention has been to provide apparatus andmethods for producing transverse seals in a folded pouch web and whichdoes not conduct destructive or excessive heat into the web on cyclestops, such that undue heat or seal propagation into the web iseliminated.

A further objective of the invention in an alternate embodiment is toprovide apparatus and methods for forming, filling and sealing pouchesin a wide range of pouch widths wherein change parts are used in subassemblies smaller, lighter, easier to handle and more repeatable thanprior devices requiring more major and potentially more expensive changeparts.

A further objective of one embodiment of the invention has been toprovide a rotary knife apparatus wherein the hubs can be changed toaccommodate pouch width changes in a wide range, but without excessivedrive lash in the hub drives.

A further objective of one embodiment of the invention has been toprovide an improved pouch forming, filling and sealing apparatus incombination with a rotary knife for accommodating a wide range of pouchwidths but without mechanical adjustment or replacement of major andminor knife hubs.

SUMMARY OF THE INVENTION

To these ends, the invention in one aspect contemplates a pouch forming,filling and sealing operation accomplished through a plurality ofseparable modules, at least one for pouch forming and one for pouchfilling and sealing. The two major modules can be spaced apart providingfor wash down of the filling apparatus without involving the formingapparatus. Alternately, the two modules can be attached together,depending on the user's desire. Operations of the web forming or sealingmodule and the respective pouch filling and sealing module areindependently controlled. But the modules cooperate to handle a widerange of pouch width configurations.

In one embodiment, for example, a web is folded upon itself and istransversely sealed continuously on a single size but adjustablevertically oriented sealer wheel mounted on a generally horizontal axis.The wheel carries adjustable, horizontally mounted heat bars. Thevertical sealer wheel is preferably operated, when used with the fillerdescribed herein, at a speed to feed the filler wheel with the propernumber of selected pouch configurations at the throughput speedsdesired.

After sealing, the transversely sealed web is then turned verticallywith the mouth between the seals opening at the top or upwardly. The webis then cut into individual pouches by a rotary knife and fed intogripper units mounted not on a chain but on an endless filler wheel orturret wheel. Each gripper unit has a fixed leading jaw and a movabletrailing jaw gripping the leading and trailing edges of the pouches,respectively. To open a mounted pouch for filling, the trailing jaw ismoved slightly toward the fixed jaw by one or more cams and held inposition by friction. Each opened pouch is carried by a gripper unit onthe filler wheel in a circular path and under a filler spout wheel unitwhere the pouch is filled as it moves through a filling arc or sector ofthe wheel rotation. Thereafter, a cam causes the gripper jaws to spreadslightly apart (the trailing jaw moves away from the leading jaw, forexample, in one embodiment, by pivoting around a horizontal axis or bysliding), stretching the mouth of the pouch closed. The pouch top ormouth is sealed in a heat sealer located in this embodiment under thespout wheel of the filler unit. Full and sealed pouched are dischargedfrom their vertical to a horizontal position by a discharge wheel to bedescribed. Other suitable discharge apparatus could be used.

In one alternative embodiment, the pouch gripper jaws are modified andare pivoted on vertical pivot axes perpendicular to the filler wheel,providing a robust gripper structure adjustable for a wide range ofpouch widths.

In addition to the foregoing, it will be appreciated that modificationsto the invention described above are contemplated, providing alternativeembodiments of varied features of the invention.

The present invention provides a pouch machine which is adjustable torun pouches over a wide range of widths in a continuous rotary wheelstyle motion at high speed and without the aid of any chains, chaintracks or sprockets, which increases productivity and reliability.

One objective of providing an improved adjustable pouch machine isattained in part by providing a single size vertically oriented sealerwheel mounted on a horizontal axis with horizontally disposed, radiallyadjustable seal bars or lands capable of heating web plies for sealing.Web entry and exit idler rollers slide respectively toward and away fromthe sealer wheel at web entry and exit points proximate the wheel and ata level above the horizontal rotational axis. This movement relaxes theweb tension across hot seal bars during cycle stop, sufficiently toallow the web to sag away from the heated lands or bars to a distance toinhibit unwanted heat or seal propagation in the web. As the rollers arewithdrawn away from the wheel, the web sags downwardly, even away fromthe vertical sealer wheel and the heated lands. Relaxing the web tensionagainst hot seal bars stops undue heat transfer and seal propagationinto the web and the pouch fill areas. Moreover, horizontal seal land orbar mounting on a vertical wheel dramatically improves web initialthreading.

An adjustable capacity pouch machine is further attained in part bydirectly mounting gripper units on a filler wheel, each gripper unithaving two jaws, between which each separate pouch is carried, theplurality of gripper units being mounted on the endless filler wheel ina uniformly-spaced relationship, but with no carrying chains orsprockets. In the gripper unit of the present invention, the leading jawis fixed and the trailing jaw is movable. The jaws may be maintainedparallel to each other regardless of the amount of separation betweenthem. The trailing jaw in one embodiment is slidably mounted on linearways and is frictionally retained in the position to which it is slid onthe linear ways. The trailing jaw has two actuators or cam followerspivoted on the gripper frame. The leading actuator, when engaged by anupwardly-inclined cam, causes the trailing jaw to retract. When thetrailing actuator cam follower rides upwardly upon an associated cam,the trailing jaw advances toward the fixed jaw. The apparatus providesas many cams as are needed for the complete sequence of operations, allcam ramps being respectively identical for actuating each jaw of eachunit respectively. In the preferred embodiment of the invention, thesequence of operations includes the following.

With the jaws open wider than the width of a separate pouch, the pouchis brought up to the leading jaw from a rotary cutoff knife by atraditional vacuum belt at a velocity slightly greater than the velocityof the gripper unit so that the pouch buckles slightly as it engages theleading jaw. A cam engages the trailing jaw actuator and advances it tograsp the trailing edge of the slightly buckled pouch. Gripping andrelease action of the jaws is also cam initiated.

The mode by which the separate pouches are transferred between a cut-offknife and the grippers may be like that described in U.S. Pat. No.4,956,964, incorporated herein by reference, or may be any othersuitable transfer mechanism.

As the pouch is carried about the filler path defined in part by thefiller wheel, it moves through an opener section, such as an air flowarea (as in U.S. Pat. No. 3,821,873 or any other suitable opener). Thetrailing jaw actuator engages another cam to advance the trailing jawslightly to a position for full opening of the pouch while air is blownacross the face of the pouch to open it. The jaws frictionally remain inthis attitude through the filling operation, where product passesthrough spouts carried by the spout wheel into the open pouch tops.After the filling operation, the trailing jaw is retracted slightly tostretch the top or mouth of the pouch taut while it is carried through apouch top sealer of any suitable form and construction.

After being sealed, the pouches are discharged, in one embodiment on adischarge wheel and the trailing jaw is further retracted or reset by afinal cam for introduction of a new pouch to be filled.

Each cam is preferably adjustable horizontally in a rotary movement toadjust the timing of the occurrence of jaw movement and adjustablevertically to determine the amount of jaw movement. The adjustments arepreferably done with hand knobs and digital counters so that settingscan be made and obtained repeatedly for the various pouch sizes. Suchgripper units may be like those described in U.S. Pat. No. 4,956,964, orof other suitable construction as described.

In an alternate form of a gripper unit, for example, the trailing jawand its pivot can be mounted without sliders, but on an adjustable platewhich can be adjusted relative to the leading jaw to accommodate a widerange of pouch widths.

In another aspect of the invention, the trailing jaw is simply rotated agreater degree toward the leading jaw for smaller width pouches, and alesser degree for wider pouches, over a wide pouch range. While thetrailing jaw for a smaller width pouch may thus engage the trailing sealedge of the pouch at a point lower than its engagement for a widerpouch, the difference is not so significant as to require a pivotadjustment for a desired range of pouch widths.

Also, a parallel linkage system may be used to retain the trailing edgejaws parallel to the leading jaws if needed.

Accordingly, in this embodiment of the invention, pouches are formed ona vertically disposed sealer wheel, cut off from the web, individuallyintroduced to a gripper unit mounted on a filler wheel and filled andsealed while on that wheel prior to discharge.

In order to cut the pouches prior to their introduction to the gripperunits on the filler wheel, a rotary knife is provided which canaccommodate pouch cut off widths through a wide range and at the speedrequired to produce a cut pouch to each gripper unit of the continuouslymoving filler wheel. More particularly, such a preferable knifecomprises a stationary anvil and a rotatable hub or spindle carrying atleast one multiple edge blade timed to cooperate and shear pouches fromthe pouch train provided by the vertical sealer wheel as described atthe transverse seals. Other knife configurations can be used. Therotational speed of the hub or hubs of the other knives are adjustedthrough servos and controls to precisely cut pouches of widely varyingwidths at the seals and at a required speed.

This apparatus for forming, filling and sealing accommodates a widerange of pouch widths with few if any change parts. For example, thesealer wheel is adjustable without change parts to effectively vary theoperational diameter and circumference of the sealing lands andaccommodates the wide range of pouch widths noted. For example, the heatseal lands are mounted on a plate and are, by means of respectiveclamps, cooperating slots and flanges and the like, radially adjustable,outwardly for wider pouches and inwardly for narrower pouches, fullyover the design range of at least about 2.5 to 5.5 inches of pouchwidth, and without concern over the effective diameter of the lands onthe wheel produced by the necessary adjustments. Such radial adjustmentcould also be accomplished by rack and pinion, gears, or other devices.A “gauge” ring could be provided so that each land is accuratelymanually adjusted to proper radial position, or the adjustments could beautomated electrically, hydraulically, pneumatically or the like. Inthis way, the vertical sealer module is adjustable without significantchange parts to produce transversely sealed pouch trains in a wide rangeof pouch widths. Moreover, the vertical sealer allows web separationfrom the sealer lands on cycle stops by way of the movable entry andexit rollers, thus eliminating undesired heat transfer into the pouchweb.

As noted above, the operating cams for the gripper jaw units on thefiller wheel, or the trailing jaw mount, or both, can be adjusted foraccommodating the desired range of pouch widths.

In order to accommodate the top sealing of the pouches after filling andon the filler wheel, the spout wheel thereabove is tilted to a greaterdegree than in past filler wheel devices handling uncut pouch trains.The entire tilted spout wheel may also be slightly spaced further abovethe filler wheel from past configurations so the spout discharge portsare disposed in a position to efficiently drop contents into thepouches, yet providing sufficient room under the spout wheel for the topsealer which may be of any suitable design and operation.

Top sealing of the pouches is performed by any suitable form of sealerafter the pouches are filled. If sealer jaws or heat lands or platensare used for the top sealing, they are mounted on sliders or othercomponents to be movable away from the pouch tops upon any cycle stop ofthe operation to prevent undue heat transfer into the pouches orundesirable seal propagation.

In another alternative embodiment, the entire top sealer for the pouchmouths above the gripper jaws is movably mounted so it can be retractedupon machine stoppage to prevent heat propagation which otherwise mightburn or destroy the pouches residing in the sealing area.

Moreover, and where required to accommodate and fill pouches efficientlyover the entire design range of widths, the spout wheel over the fillerwheel is provided with changeable spouts. Thus, a set of spouts can bechanged out to another set of spouts to accommodate different pouchwidths and without requiring the entire spout wheel to be changed. Thespouts can be releasably snapped into place on the same spout wheel,resulting in very quick changeover, where needed. The change spoutdischarge ends can be angled or positioned differently from anotherspout set to efficiently fill the pouches, for which the change spoutsare designed.

Alternately, the spout plate could be phased to match the spouts withthe pouch openings so no replacement spouts are required. Or both changespouts and phasing can be used in combination.

In this regard, the spout wheel and the filler wheel mounting the pouchgrippers are effectively driven by separate and independently controlledservo drives. These are controlled so as to properly phase the dischargeends of the spouts with the particular pouch widths or pitch on thefiller wheel. By this alternative, a wide variety of pouch widths can befilled with only a servo drive adjustment for alignment purposes.

Also, in this embodiment, a discharge wheel is disposed downstream ofthe top sealer adjacent the filler wheel to remove filled and sealedpouches from the gripper units. This discharge wheel includes aplurality of vacuum cups for engaging pouches in the gripper units andtransporting pouches away from the gripper units and filler wheel whenthe grippers are cammed or operated to release the pouch and reset forthe next empty pouch pickup.

Preferably, two vacuum cups are mounted at each pouch station of thedischarge wheel on a pivoted arm. The arm is pivoted beneath the cups tothe wheel. These arms are vertically disposed on vacuum cup engagementwith the pouches, then pivot outwardly and downwardly so the pouches arereceived in a vertical disposition then rotated away from the filler toa horizontal position for discharge upon vacuum cup release. Thereafter,the arms are raised for another discharge cycle as the discharge wheelrotates. The speed of the discharge wheel is timed and phased with thatof the filler wheel, such as through servos, for the wide range of pouchwidths, on the filler wheel.

Alternately, two opposed pinch belts comprise a pouch pinch nip along apouch pitch line tangentially from the filler wheel downstream of thetop sealer. Sealed pouch tops are grasped while leading, then trailinggripper jaws sequentially release their hold on the pouch edges. Thebelts transport the individual filled and sealed pouches for downstreamhandling or packaging.

It will be appreciated that components of this invention can be providedin modules so as to provide a high degree of flexibility in system andfloor plan design. For example, the web feed and vertical sealer wheelcan be provided in one heat sealing module, operably connectable with orseparate from a variety of pouch filling and sealing apparatus,including that described in the embodiments above. If the vertical wheelheat sealing module is separate or easily separable from the fillingwheel module, for example, wash down of the filling area withoutcontaminating the heat sealing operation is provided.

Moreover, it will be appreciated that the filler wheel as describedabove can be fed directly from the vertical wheel heat seal apparatus asdescribed, or it could be fed separate pre-cut pouches from a magazineand without the need for a transverse heat seal operation at the timeand location of the filling and sealing apparatus, thus providing evenmore manufacturing flexibility and flexibility in pouch inventorymanagement. This also further demonstrates the lack of need for acoordinated mechanical drive system as in prior units requiringsignificant change parts on pouch width changes.

In this regard, it is to be appreciated that the vertical sealer wheelon one hand and the filler wheel on the other are preferablyindependently driven by separate servo drives so they can be coordinatedwith each other or with other modules or components with which they areused.

Thus, in an alternative embodiment of the invention for pouch handling,it will be appreciated that the vertical sealer wheel disclosed can beused in other pouch handling, filling and sealing applications notlimited to the filler and sealer as also described herein.

In another aspect of the invention, the same vertical sealer wheel isused, however, the formed pouch train is not cut before filling.Instead, the pouch train is introduced intact to the filler wheel wherethe transverse seals are engaged by vacuum lands on the feeder wheel.The pouches are opened traditionally, for example, as shown in U.S. Pat.No. 3,821,873, filled, top sealed, then cut off by a rotary knife.

In this embodiment of the invention, a different combination of elementsare used to accommodate a wide range of pouch widths in the range of atleast about 2.5 to about 5.5 inches. No gripper units are used in thefiller wheel. Instead, change out filler wheels are provided in anannulus, donut or ring form, each of which is preferably within only twoto three inches variation in outer diameter of the other. Vacuum landsare mounted about each wheel with a radial spacing from the axis toaccommodate the particular pouch size. Vacuum port sets for each fillerwheel are provided in distinct radial distances from the center axis ofa vacuum shoe. The ports of the wheel cooperate with a designated set ofports in the shoe at a designated radial distance from the center foroperation with designated pouch widths. Thus, the vacuum shoe has aplurality of port sets, each in a distinct radial distance from thecenter and each port set cooperating to convey vacuum to a distinctvacuum land annulus or donut ring carrying the vacuum lands. Thus, tochange over for pouches of varied width or pitch, it is only necessaryto replace a relatively inexpensive donut or ring with associated vacuumlands, and not the entire filler wheel or vacuum shoe in thisembodiment.

Alternately, a changeover could be made with changeable donuts where thesame land are quickly changed over from one size donut to another.

A further embodiment could accomplish changeover for different pouchwidths by retaining the same donut or ring and replacing the vacuumlands with a different set of lands providing different pouch chordlengths about the filler.

Alternately, the vacuum lands can be radially adjustable in radial slotson the same ring to provide varying land spacing and chord distancebetween them or handling a range of pouch widths.

Alternately, other forms or structures for providing vacuum to thedifferent vacuum lands can be used.

In this embodiment, the spout change out provisions of the embodimentdescribed above can also be used. Alternately, very lightweight spoutplates, each in the form of an annulus and carrying lightweight spoutsspaced for the particular pouch width desired can be changed out.

Once filled, the pouch train of this embodiment is top sealed and thetrain of sealed pouches transported to a knife for individual pouchcutoff.

In the past, rotary pouch cutoff knives have been used for thisoperation and some of these have been adjustable. See, for example, therotary knives described in U.S. Pat. Nos. 4,872,382; 5,222,422;5,829,332; 5,575,187; 6,058,818 and 6,553,743, each of which isexpressly incorporated by reference as a part hereof. In one form ofprior knife, the package guides have been slightly radially adjusted toaccommodate varied pouch widths.

In order, however, to accommodate the wide range of filled and sealedpouches now desired, such as about 2.5 to 5.5 inches in width, variousknife hubs must be provided in effective diameters beyond thatattainable by the adjustment range of these prior knives.

One problem with change out of different diameter major and minor knifehubs is that the distance between their respective axes of rotation mustbe changed since the effective knife hub diameters are significantlychanged. This requires accurate drive gears on the ends of each hubshaft to avoid drive lash and change-out parts which are expensive.

This invention contemplates an improved knife where the wide range ofpouch widths is accommodated by major and minor knife hub change partsand the combination therewith of a four-gear anti-lash drive train,pivotally mounted to accommodate changes in the distance between therespective rotational axes of the hubs.

Each knife set up for a selected pouch width includes a set of major andminor knife hubs with respective effective diameters for the widthselected. Other sets have different effective cooperating hub diameterswith different spacing required for their parallel drive axes.Accordingly, an upper, minor knife hub is mounted on a minor hub shaft,the axis of which is journaled in a movable bell housing. When released,the bell housing can be moved to change the distance between the minorhub axis and the fixed major hub axis, accommodating different diameterknife hubs.

A drive gear is mounted on the major knife hub, and a slave gear on theshaft of the minor hub. Two meshed anti-lash gears are mounted on apivoted gear arm with one of these gears engaging the drive gear and theother the minor hub shaft slave gear.

When the knife hubs are changed, the gear arm is adjusted to accommodatethe different center-to-center distance between the fixed axis of themajor knife hub and the repositioned axis of the minor knife hub.Specifically, the axis on the first anti-lash gear is coaxial with thegear arm pivot. The axis of the second anti-lash gear is fixed on thearm with respect to the axis of the first anti-last gear, but is movableaway from gear engagement as the arm is pivoted with respect to theslave gear on the minor hub axis to accommodate its movement withrespect to the drive gear and major hub axis. Once the minor hub is set,the gear arm is pivoted to re-engage the slave gear on its axis and theanti-lash drive thus reestablished, even though the spacing between themajor and minor hub axes has changed.

In addition, the major knife hub is provided with radially adjustablepackage guides to handle a range of pouch widths. However, themechanisms by which the package guides of the major knife hub areradially adjusted Is different from that of prior mechanisms. The prioradjustment cones shown in the prior patents are eliminated. Instead, therespective package guides are mounted on threaded, extensible carrierrods having beveled gears on their radially inner ends. Each of theseengages a common beveled drive gear which is phase adjustable throughthe major knife hub structure to change the radial extent and thus thecircumferential spacing of the package guides for fine tuning of thepouch widths or chords desired.

This knife apparatus eliminates the weight and complexity of the priorscrew and cone adjustable knife hubs, rendering the cutting operationsfor varied pouch widths over the design range less expensive and at thesame time adjustable over a wider pitch range. Thus, while it iscontemplated that while knife hub change out may be required to meet theextremes of the design pouch range from about 2.5 to 5.5 inches inwidth, the hubs are lighter than prior devices. At the same time, theuse of the four-gear drive provides accurate registration, hubcooperation which accommodating varied shaft spacing.

Accordingly, while this alternate pouch forming, filling and sealingembodiment involves more change-out parts than the prior embodimentdescribed, it yet requires fewer and less complex change-out parts thanprior systems for the desired pouch width variation ranges.

These and other objectives and advantages of the invention will bereadily appreciated from the foregoing, and from the followingdescription and drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above and thedetailed description given below, serve to explain the invention.

FIG. 1 is an illustrative view of one embodiment of pouch forming,filling and sealing according to the invention, with a vertical sealerwheel module and a filler/sealer wheel module;

FIG. 1A illustrates in elevational view of an alternate vertical sealerto that of FIG. 1;

FIG. 2 is an illustrative elevational view of a horizontal shaft,vertically oriented, transverse sealer wheel according to the inventionand also showing the pouch web in relaxed position around the wheel inphantom;

FIG. 3 is an illustrative side view of a vertical sealer wheel of FIG. 1(shown for clarity on its side);

FIG. 4 is an illustrative perspective view of the respective sealinglands of the vertical sealer wheel of FIGS. 1-3;

FIG. 5 is an illustrative perspective view of the knife, filler wheel,sealer and discharge wheel according to one embodiment of the inventionbut with the filler wheel and gripper units removed for clarity;

FIG. 6 is an illustrative top view of the spout wheel over the fillerwheel and discharge wheel according to one embodiment of the invention;

FIG. 7 is an illustrative elevational view of the spout wheel, fillerwheel and discharge wheel of one embodiment of the invention of FIGS.1-6 but omitting detail of the pouch gripper units and the knife forclarity;

FIG. 8 is an illustrative bottom view of the spout wheel, top sealer anddischarge wheel of one embodiment of the invention of FIGS. 1-7, withthe knife and filler wheel removed for clarity in this view;

FIG. 9 is an illustrative elevational view of one embodiment of agripper unit having a leading jaw and a trailing jaw pivotally mountedon an adjustable mounting plate according to the invention;

FIG. 9A is a top view of leading and trailing pouch gripper jawsaccording to the invention of FIGS. 1-9;

FIG. 9B is a perspective view illustrating the gripper jaws of theinvention of FIGS. 1-9A;

FIG. 10 is an elevational view of an alternate gripper unit with aparallel link mount;

FIG. 11 is an illustrative perspective view of an alternate embodimentof the invention with pouches in a pouch train being filled and sealedbefore cutting;

FIG. 12 is an illustrative exploded view of changeable filler and spoutwheels of one alternate embodiment of the invention as in FIG. 11;

FIG. 13 is an illustrative perspective view of a changeable rotary knifeand knife drive according to the invention;

FIG. 14 is an illustrative perspective view of the rotary knife of FIG.13 viewed from the knife hub side;

FIG. 15 is an illustrative view of the adjustable pouch guides of themajor hub of the knife of FIGS. 13 and 14;

FIG. 16 is an illustrative view of the pouch guides of FIG. 15 butviewed from the opposite side of FIG. 15.

FIG. 17 is a bottom view of an alternative preferred gripper jawembodiment of the invention with gripper jaws pivoted on vertical pivotaxes perpendicular to the plane of rotation or surface of a fillerwheel;

FIG. 18 is a perspective view of an alternate pinch-belt pouch dischargefrom a filler according to the invention;

FIG. 19 is a perspective illustration of an alternate top sealer of theinvention, movable vertically and horizontally between sealing andretracted positions to prevent undesired heat propagation into the pouchfilm upon emergency or cycle stops or the like; and

FIG. 20 is an elevational view of an alternate embodiment of theinvention showing alternate gripper jaws of FIG. 17 mounted on a fillerwheel, and the upper spout plate (with spouts removed for clarity) andillustrating the separate and independent servo drives for the fillerwheel and spout plate, respectively.

DETAILED DESCRIPTION

Turning now to the drawings, it will be appreciated that FIGS. 1-9Billustrate various features of one embodiment of the invention, forexample, where the pouches are formed on the vertical sealer wheel thenseparated before they are introduced to a filler wheel. The separatedpouches are thereafter filled, sealed and discharged.

In another embodiment of the invention, such as shown in FIGS. 11 and12, the pouches are formed on the vertical sealer wheel, but areintroduced to the filler wheel in a pouch train, where the pouches arefilled, the tops are sealed, and thereafter the pouches are cut off, onefrom the other, for discharge.

Other embodiments of the invention or components of the two embodimentsdescribed above are shown in the additional Figures.

Turning now to FIGS. 1-9B, a first embodiment of the invention will bedescribed, FIG. 1 illustrates the overall layout of the first embodimentof the invention. In FIG. 1, there is shown a vertical sealer 10,preferably constructed as a first sealer module 11 with a verticallyoriented sealer wheel rotatable about a generally horizontal axis. Fromthe vertical sealer 10, the web W is transported to a knife apparatus12, illustrated in a knife module 13. This is also clearly illustratedin FIG. 5, and it will be appreciated that the module 12 also includes avacuum belt transport 14 for conveying cut pouches from the knife 12 tothe filler wheel as will be described.

With further reference to FIG. 1, the individual pouches are introducedto respective gripper units 16, mounted on the filler wheel 18 of afiller module 19. One such gripper unit 62 is shown, for example, inFIGS. 9, 9A and 9B as will be described, while other alternativegrippers are shown in FIGS. 10, 17, 19 and 20.

Filler wheel 18 is generally circular and resides under a spout wheel 20(as shown in the various figures), carrying a plurality of spouts 22. Asperhaps best seen in FIG. 7 the spout wheel 20 is tilted at an anglewith respect to the filler wheel 18. Such angle may be, for example,approximately three degrees. As viewed in the right hand side of FIG. 7,the spouts are positioned downwardly and over the pouches, so that thetransfer of product can be efficiently made from the bottom dischargeopening of the spouts into the pouches as will be described.

Once the pouches are carried about the filler wheel through a fillingsector as will be described, the tops of the filled but still openpouches are tensioned by moving the pouch edges apart so that the topsclose. Tops of the pouches are then sealed, such as by a sealerapparatus 24, as shown in FIGS. 5 and 6, for example.

Once the pouch tops are sealed at sealer 24, they may be run through afinal crimp roller, such as at 26 in FIG. 1 and from there, aretransferred to a discharge wheel 28, as will be described. The dischargewheel of this embodiment removes the vertically oriented pouches fromthe filler wheel 18 and rotates the pouches to a horizontal position fordischarge and further transfer to pouch packaging or further treatmentequipment.

Turning now to FIGS. 1-4, the vertical sealer 10 will now be described.It will be appreciated this vertical sealer preferably comprises a pouchforming module which can be used or coupled with the filler module 19 orin other web or pouch handling operations as appropriate.

FIGS. 1 and 2 perhaps best show the general features of the verticalsealer 10. As illustrated in the figures, a web supply, such as 30, ofany suitable design, feeds a folded web W to the vertical sealer 10.Preferably, a web is folded longitudinally to provide a folded, multipleply web with the fold comprising the bottom of the to-be-formed pouches.Alternately, two plies, sealed along one edge to form the pouch bottomcould be used. In particular, in a preferred embodiment, the folded webW is fed through appropriate web control rollers 32,33 to an entryroller 34. From there, the folded web W is entrained about a verticallyoriented sealer wheel 36, provided with a plurality of horizontallyoriented heated sealing lands 37. Sealer wheel 36 is mounted on agenerally horizontal axis for rotation in a generally vertical plane.From the vertical sealer wheel 36, the web is entrained about a web exitroller 38; through a web roller control apparatus 39, of any suitableconstruction, including dancer rollers or the like, as shown in FIG. 1,and from there the web is introduced as shown in FIG. 1 to the knifemodule 13. When the web exits the wheel 36, a plurality of seals hasbeen placed in the web to define a train of open-top pouches.

As shown, in FIG. 1, the web entry roller 34 and exit roller 38 of oneembodiment are mounted on a pivoted arm mechanism 40. Specifically,retractable or movable rollers 34, 38 are mounted on the respectivepivot arms 41, 42, which are in turn secured to respective pivot arms43, 44, which have distal ends pivoted to a fixed pivot 45.

Any suitable drive mechanism is used to pivot the arms about the fixedpivot 45. This pivots the respective interconnecting arms 43, 41 and 44,42 so as to extend the web entry roller 34 and the web exit roller 38outwardly and away from the sealer wheel 36.

Accordingly, it will be appreciated that when the rollers 34, 38 are inthe solid-line, web-tensioning positions shown in FIGS. 1 and 2, the webW is tensioned about the sealer wheel 36, so that the web is urgedagainst and engages the heated sealing lands 37. This engagement of themultiple ply web with the heated lands forms transverse seals across theweb from the folded bottom to the upper edges of the plies defining openpouch tops, thus forming a web having a plurality of transverse sealsspaced apart and defining open top, individual pouches, butnevertheless, each pouch still being a part of an unbroken web.

On the other hand, upon cycle stops, for example, when wheel 36 isstationary, the rollers 34, 38 are moved apart and away from thevertical sealer wheel 36 to respective web relax positions such that thetension in the web is relaxed and it takes on the relaxed configurationas shown in the phantom lines 46 of FIG. 2 where it will preferablydisengage from the lands 37. These lines are approximations,illustrating that the web tension is relaxed and the web falls away fromthe heated lands of wheel 36. In this configuration then, the tension ofthe web against the lands 38 is relaxed and this relaxation spaces thefolded web from lands 38, thus inhibiting transfer of heat from thehorizontal sealing lands to the multiple plies of the web. This preventstransfer of undue heat to the web and prevents undesired sealpropagation in the web.

Thus, where the web entry and exit rollers 34, 38 are moved away fromthe sealer wheel 36, the web may sag downwardly and away from the wheel,such that it is no longer in contact with the lands or, while the webmight still contact the lands, it is not held against the lands withsuch tension that undue heat is transferred. The motion of the rollers34, 38 are indicated by the arrows 47, 48 respectively, in FIG. 2.

In an alternate and preferred configuration, shown in FIG. 1A, avertical sealer 240 includes tension rollers 34 a, 38 a mounted onelongated tracks 241, 242 oblique to the filler wheel 36 or on the axis49 a. Movement of rollers from one to another position along the trackresults in a similar web relaxation, allowing the web to sag from thewheel 36 and its heated lands, preventing undue heat propagation in theweb upon emergency, cycle or other stops. Rollers 34 a, 38 a are movedbetween web tensioning positions shown in solid lines and web relaxedpositions shown in phantom. When rollers 34 a, 38 a move closertogether, multiple ply web W is tensioned against sealer wheel 36 a.When those rollers are moved away from one another, the web tension isrelaxed and the web preferably moves away (phantom lines) from wheel 36a.

With respect to both vertical sealer embodiments, it will be appreciatedthe distance between rollers 34, 38 and 34 a, 38 a is less than thediameter of the sealer wheel 36 or 36 a, at least in the web tensioningposition.

It will be appreciated that the rollers are moved obliquely by anysuitable expedient, including but not limited to, the embodiments shownand other hydraulic or pneumatic cylinders, solenoids, linear motors orthe like.

It will also be appreciated that the web supply 30 diagrammaticallyillustrated in FIGS. 1 and 2 could be defined as part of the sealeroperation module or could itself be defined in a separate module, forexample, located at a position adjacent or just behind the sealer module11.

Turning now to FIGS. 3 and 4, there is illustrated in these figuresvarious views of a vertical sealer wheel according to the invention. Itwill be appreciated that the vertical sealer wheel in operation isvertically oriented about a horizontal axis illustrated at 49 in FIG. 1so that that axis is also parallel to the horizontally-orientedelongated heat sealing lands 37.

Taking a closer look at sealer wheel 36 in FIGS. 3-4, it will beappreciated that the sealer wheel 36 is generally circular and isprovided with a plurality of slots 50 in one wheel surface extendingradially outward from the center of the wheel. Each of these slots, forexample, may comprise in cross-section, a T-shaped configuration asillustrated in FIG. 3. A plurality of heatable sealing lands 37 aredisposed within the slots 50. Each of the sealing lands has a top rib,such as at 51, fitting within the T-shaped slots 50 so that the land canbe moved in a radial direction with respect to the wheel and the slots.

Each of the lands is also provided with a clamping apparatus such as ahandle 52 adapted to screw into the upper portion of the land, where itengages the wheel, and adapted to be tightened to secure the respectiveland in position slot 50. Thus, each land can be moved radially inwardlyand outwardly on the wheel and set by means of the clamping handle 52.The particular structural features of the upper portion of the lands 37and the clamping handles 52 can be provided in any suitable design.

It will be appreciated then, that the lands can be adjusted by thismeans and that the effective diameter and circumference of the lands andvertical sealer is thus set by, and dependent on, the radial position ofthe lands 37 on the sealer wheel 36.

Accordingly, for pouches of wider dimension at the extreme end of therange, for example, the lands can be moved radially outwardly. To handlesmaller pouches, the lands are moved radially inwardly, so that thechord length, that is the distance between each of the lands, ischangeable over the range or selected range of pouch widths to behandled on the vertical sealer while the wheel 36 itself remains thesame circumference and diameter. Without change parts, the verticalsealer thus accommodates a wide range of pouch widths.

In this regard, it will be appreciated that the web entry and exitrollers 34, 38 can be adjusted so as to properly, tension the web aroundthe sealer wheel for all selected pouch dimensions (and landcircumferences) within the design range.

Finally, it will be appreciated that each of the lands is provided witha heater apparatus as is well known in the art and of any suitableconfiguration and variety, in order to present heated land surfaces tothe film to be engaged thereon, so as to impart the appropriate amountof heat to the web film and create a seal between the folded web sides.

Turning now to FIG. 5, the transversely sealed web W-1 is transported toknife module 13. There, the individual pouches P are cut off, separatedfrom the web W-1 and are transferred by any suitable vacuum belt 54 togripper units 16 mounted on the filler wheel 18. Each gripper unit maybe constructed in any suitable form, such as, for example, the gripperunit shown in U.S. Pat. No. 4,956,964. Alternately, the gripper unitsmay take the form, for example, illustrated in FIG. 9 to 10 or 17, 19,or 20 described below.

In any event, it will be appreciated that each gripper unit, includingthe jaws thereof, is preferably mounted on or directly to the fillerwheel. They are not mounted on or carried by chains as was the priorcustom. The gripper units define pouch stations about the filler wheel.Each gripper unit is operable to receive the unfilled pouch feeding fromthe knife 12 to facilitate opening of the pouch, to hold the pouch whileit is being filled, to facilitate closing and top sealing of the pouchand thereafter being reset to receive further pouches from the knife asthe filler wheel 18 rotates.

This entire cutting, filling, sealing and discharge operation isillustrated, for example, in FIG. 5, with various features thereof alsoillustrated in FIGS. 6-8. From FIGS. 5 and 6, it will be appreciatedthat the pouches P are introduced to the filler wheel 18 at one point onthe wheel, and thereafter the pouches are conveyed through filling,closing, product settling and sealing sectors to the discharge wheel 28and the discharge sector, where the pouches are removed from the gripperunits 16 on the filler wheel 18 and are reoriented from a vertical to ahorizontal disposition for later discharge.

In this regard, it will be appreciated that the filler wheel rotates inthe direction of the arrow 55 (FIGS. 5-6) while the discharge wheel 28rotates in the direction of arrow 56 (FIGS. 5-6) for transferring thepouches from wheel 18 to discharge.

With particular respect to the discharge wheel 28, it will beappreciated that the wheel has a plurality of pivot arms 58. Each pivotarm 58 is pivoted at its bottom to the discharge wheel 28 and eachpreferably carries with it two suction cups 59, 60 for attaching to theclosed pouches.

In operation, the suction cups 59, 60 attach to the outside surface of apouch while it is retained in the gripper units 16 on the filler wheel18. Once vacuum is established by the cups 59, 60 on the outside surfaceof the pouch, the gripper units are operated as will be described,releasing the pouches as the discharge wheel continues its rotation inthe direction of arrow 56. At the same time, the pivot arms 58 arepivoted at the bottom to move the pouches from the vertical orientationon the filler wheel 18 to the horizontal orientation as illustrated inFIGS. 5-8, thereby removing the filled and seal pouches for dischargefrom the operation. Vacuum ceases or pressure then applied to eject thenow horizontal pouches. Thereafter the pivot arms 58 are rotated totheir vertical position, where they can serve to introduce the vacuumcups 59, 60 thereon to further pouches being discharged from the fillerwheel 18. Pivot arms 58 can be cam operated and any appropriatevacuum/pressure control used to energize the cup suction or discharge.Thus, the discharge wheel facilitates the orienting of dischargingpouches to a horizontal position.

It will be appreciated that FIGS. 5-8 also illustrate the spout wheelwhich is located above the filler wheel 18. The spout wheel 20 carries aplurality of spouts 22 for motion in a circular path in a plane which isoriented at an angle with respect to the circular path in a plan definedby the rotation of the filler wheel 18. The spout wheel 20 supports aspouts 22 and is phased with the filler wheel to present lower or bottomdischarge ports of the spouts 22 in the proper position for filling intorespective pouches carried by the filler wheel 18.

As the spout wheel 20 rotates above the filler wheel 18, it will beappreciated that the spouts 22 on the right hand side of the apparatusas shown in FIG. 7, move toward the pouches P in the pouch fillingsector (FIG. 6) but then the spouts are inclined upwardly and away fromthe filler wheel 18 as they move toward the closing sector (FIG. 6).This is in order to clear the sealer apparatus 24 which can be mountedon reciprocable rods as indicated in FIG. 7 for selectively engaging andthen withdrawing from the tops of the pouches to seal them. It will beappreciated that the hot air sealing apparatus 24 is substantiallydisposed beneath the spout wheel 22 and above the filler wheel 18, or atleast the outer circumference thereof.

Brief reference is made to FIGS. 9-10 showing two different embodimentsof a gripper unit 16. As previously stated, the gripper unit 16 can beany suitable form of gripper unit such as, for example, that shown inU.S. Pat. No. 4,956,964. Alternately, the gripper unit can be any formof gripper unit such as shown in FIGS. 9-10. In any event, the gripperunits are mounted on or to the filler wheel 18.

With respect to FIG. 9, for example, a gripper unit 62 is illustratedand includes a fixed, leading jaw 63 and a pivoted trailing jaw 64. Asused herein, the term “jaw” is sometimes used to mean both the clampingstructure and/or the carrying arms on which the clamping structure iscarried. Leading jaw 63 is preferably fixed to or directly mounted onthe filler wheel 18 or to intermediate components fixed to the fillerwheel. Trailing jaw 64, however, is mounted on a jaw actuator arm 65pivoted at 66, to a bracket 67. Bracket 67 is adjustably secured to thefiller wheel 18 by any suitable means, such as bolts and slots providedwithin the respective wheel 18 and bracket 67. The bracket 67 can thusbe adjusted in the direction of arrow 68, so that the jaw 64 can beadjusted toward or away from the leading jaw 63 to accommodate a widerange of pouch widths, without requiring change parts.

The gripper jaw actuator arm 65 is provided with cam followers 69, 70,which are respectively engaged by cams situated about the filler wheel18 for moving the jaw 64 in appropriate directions (arrow 68) toward andaway from the leading jaw 63 as the gripper unit 62 is transported aboutthe circumference defined by the filler wheel 18 in the direction ofarrow MD. As previously stated, various cams are provided for engagingcam followers 69, 70 to move the actuator in the direction of arrow 71about pivot point 66. Any suitable adjustable cam structure can be used.

In operation, the bracket 67 is adjusted, for example, toward or awayfrom the leading jaw 63, so that the trailing jaw is brought intoposition for handling the particular pouch width being handled. It willbe appreciated that both the jaws 63, 64 extend outwardly from the paperin the view of FIG. 9 to grasp a sealed edge of the cut pouch presentedto the gripper unit 67 (see FIG. 9A).

As the gripper unit is transported about the circumferential pathdefined by the filler wheel 18, a pouch from knife 12 is first grippedby the jaw 63. Thereafter, the trailing jaw 64 is pivoted by actuatorarm 65 to catch up to the opposite trailing side of the pouch and togrip it along the seam. This motion also moves the trailing pouch edgetoward the leading edge seam to slightly open the pouch mouth by movingthe edge seals closer together, so that the top edges of pouch web sidesare slightly buckled or opened.

Thereafter, the pouches can be further opened by any suitable mechanism,such as an air flow, and filled as they traverse through the fillingsector (FIG. 6) defined by the filler wheel 18. After filling, the jawactuator 65 is rotated by appropriately adjusted cams to pivot thetrailing jaw 64 in the opposite direction away from leading jaw 63 aboutpivot 66 to stretch the mouth of the pouch tight for sealing.

In a slight alternate embodiment to this, it may be possible to size theactuator 65 and the location of the pivot point 66, such that theadjustable bracket 67 could be eliminated, and thus use adjustablemotion of the actuator 65 and the jaw 64 to accommodate the full rangeof pouch widths to be handled. In such a configuration, of course, itwill be appreciated that the jaw 64 will engage the trailing edge of thepouch at a higher level than the same jaw 64 would engage the trailingedge of a smaller width pouch. Of course, a variety of cam structurescan be used to actuate the jaw actuator 65 for either of theseembodiments.

FIG. 9A illustrates the structure and operation of the clamping elementsof the jaws 63, 64. Each jaw clamping structure comprises an anvil 85, amovable clamp member 86, a spring 89 and a pivot arm 87 carrying theclamp member 86. A cam follower 90 is mounted on a distal end of arm 87and is moved by a cam (not shown) to pivot about axis 88 to open orclose jaws 63, 64 at the appropriate timing sequence. These respectivejaw clamping parts are similar, with trailing jaw 64 being generally amirror image of leading jaw 63 as viewed in FIG. 9A. Springs 89 are usedto bias the respective clamping elements 86 toward the anvils 85. FIG.9B illustrates the motion of jaws 64, 63 of FIG. 9A relative to eachother to respectively open the mouth M on the pouch P for filling, andthen to close the pouch mouth M.

Turning now to FIG. 10, an alternative form of gripper unit 74 isillustrated. In this unit, which is somewhat similar to the gripper unit62 described above, the trailing jaw structure 76 is mounted on aslidable bracket 67, such as that bracket in the preceding embodiment,and is provided with a parallel link construction 75 with a pivotmounting on actuator arm 77 so that the trailing jaw 76 is alwaysmaintained in a parallel condition with respect to the pouch to behandled. Thus, as the actuator arm 77 is rotated about the pivot point78, the jaw 76 remains essentially parallel to leading jaw 79 forengaging the pouch. In this regard, the leading jaw 79 is similar tothat jaw 63 of the embodiment of FIG. 9. The clamping elements of jaws76, 79 can be described above.

In the embodiments of FIGS. 9-10 inclusive, it will be appreciated thejaws 63, 64, 76,79 are mounted on or to filler wheel 18. It will also beappreciated that the clamping elements 85, 86 are mounted for rotationabout vertical axes 88, perpendicular to filler wheel 18 or thehorizontal plane in which filler wheel 18 rotates, with axes 88 parallelto a vertical axis about which horizontal filler wheel 18 rotates. Thisis contrasted to the motion of the trailing jaws 64, 76 mounted forrotation about axes 66, 78 respectively, which are perpendicular to thevertical axis about which filler wheel 18 rotates. Accordingly, therespective clamping elements of the jaws rotate about vertical axeswhile the jaw structure rotates about horizontal axes for pouchreceiving, opening, closing and discharge.

A yet further jaw embodiment is illustrated in FIGS. 17, 19 and 20. inthis preferred embodiment, comprising an alternative gripper unit 175,trailing jaw 176 and leading jaw 177 are used to clamp, handle andsupport a pouch P as do the respective leading and trailing jaws of theprior embodiments. As well, the clamping elements and anvils of the jawsare similar. This embodiment differs from the prior embodiment inseveral respects, including the rotational movement for both pouchclamping and for pouch receiving, opening, closing and discharge beingabout vertical axes, perpendicular to wheel 18, 181 and parallel to thevertical axis about which wheel 18, 181 rotates.

Accordingly, the pouch engaging elements of leading jaws 177 aresupported on pivot arms 178 and those of the trailing jaws 176 on pivotarms 179, both arms operating pouch clamping elements and anvils as inthe prior embodiments, and both rotatable about respective vertical axes185, 188.

Cam followers 190 operate the spring loaded clamping elements aboutrespective axes 188 to pinch or release pouch seams against respectiveanvils as in the other gripper embodiments.

Departing from that prior construction, however, lead jaws 177 aremounted to a component 180 of a filler wheel 181 (only segment 180 shownin FIG. 17). The trailing jaws 176 are mounted on another pivot arm 184,each pivoted at an axis 185 to segment 180 of a filler wheel 181. Axes185 are disposed perpendicularly to filler wheel 181 or the plane inwhich it rotates, and parallel to a filler wheel axis. One end 186 ofarm 184 carries a cam follower 187 driven by an appropriate cam 192 toadjust the relative position of trailing jaws 176 to cooperating leadjaws 177. This accommodates pouches of varying width “W” (FIG. 17), andprovides a very thin jaw profile (in elevational view—see FIG. 20). Itwill be further appreciated this thin profile, as compared to the priordescribed jaw embodiments, is provided by mounting the trailing jawstructures to an arm provided on an axis 185 perpendicular to the fillerwheel 181, so the overall structure of the jaw mounting element extendsin a radial direction from an axis of rotation of filler wheel 181,rather than being vertically disposed in the periphery of the wheel asin the other embodiments.

Accordingly, one cam 192 is used to facilitate pouch edge gripping andanother cam drives cam followers 187 to adjust the relative jawposition. Such a cam 192 can be advanced or retarded in the direction ofarrow A and thus adjusted to accommodate a wide range of pouch widths W.

It will thus be appreciated that respective components of gripper units62, 74 rotate about respective axes perpendicular to each other whilecomponents of gripper unit 175 rotate about respective axes parallel toeach other.

With attention now to the adjustable operation of the filler and FIGS.1-10, it will be appreciated that individual pouches P are introduced toa suitable gripper unit, such as 16, 62, 74 or 175, and is transportedabout a path defined by the filler wheel 18. In order to handledifferent sized pouches, that is pouches of different widths, and in therange of, for example, 2.5 to 5.5 inches in width, the gripper units onthe filler wheel 18 are individually adjusted, as heretofore noted, sothat the operable distances between the leading and trailing jaws,respectively, is adjusted to handle the particular pouch size.

In addition, the spout wheel 20 is provided with a plurality ofremovable snap-in spouts 22 and knife edges 82, which define theseparation point between the respective spouts 22. When it is desired tochange over from one pouch size to another, the pouches 22 are providedwith snap-in connection to the wheel 20 and can easily be removed fromthe wheel 20 with new pouches 22 snapped in. New pouches 22 may beprovided with slightly varied angles of approach, for example, to thedischarge point for accurately depositing product in the new size ofpouch. In addition, the knife edges 82 can also be provided with asnap-in construction, so that they can be changed when necessary, or theknife edges 82 can be retained in position.

In addition to this, it may or may not be necessary to phase the spoutwheel 20 with respect to the filler wheel 18 so that the bottomdischarge opening of the respective spouts to be used are accuratelylocated with respect to the open mouths of the pouches on the fillerwheel 18. Any appropriate structure, as is well known, can be utilizedto transfer product into the spouts from above the spout wheel 20 forfilling into the pouches. After the pouches are filled, the gripperunits are preferably operated to stretch the mouths of the pouchestogether, so that they can be sealed in the top sealer unit 24.

Sealer unit 24, as noted, comprises reciprocal sealing jaws which can beoriented to seal the mouths of the pouches as they move through therespective jaws or sealer apparatus. The sealer apparatus is alsomounted on reciprocal rods as indicated, for example, in the figures,including FIGS. 6 and 7, so that the movable jaws or elements of thesealer can be laterally moved away from each other and away from themouth of the pouch when any stoppage, such as a cycle or emergency stopor shutdown of the equipment, is commanded, so as to prevent unduetransfer of heat into the pouches, as would destroy them or render themunacceptable.

For discharge downstream of the filler wheel 18, such as shown, forexample, in FIGS. 5-7, it will be appreciated that the pouches areengaged by the discharge wheel 28 and removed or released from thefiller wheel 18 in a pouch discharge sector 56 discharging pouches fromfiller wheel 18 and from filler module 19. It is during this operationthat the pouches are transferred from a vertical to a horizontalorientation for discharge.

It will also be appreciated that the speed of rotation of the wheel 28and its alignment is coordinated with the speed of the filler wheel andthe pitch line of the pouches on the filler wheel 18, so that thesuction cups and pivot arms of the discharge wheel 18 are accuratelylined with pouches as they come from the sealer to facilitate thedischarge operation.

In connection with the introduction of separate pouches to the gripperunits used, it will be appreciated that the knife 12 can be of anysuitable construction. One form of knife includes two knife hubs, eachwith extending knife blades, as diagrammatically illustrated in thefigures. These two knife hubs can be rotated at a speed, such that twoof the blades come into shear orientation in the center of the sealswhich have been provided by the vertical sealer apparatus.

In order to adjust the knives to accommodate pouches of differentwidths, it is only necessary to adjust the speed of the two hubs so asto shear pouches from the web train presented to it in the appropriatedistance, as will be appreciated. Thereafter, pouches are transferred tothe filler wheel and the gripper units by means of a vacuum belt as iswell known in the art.

In one embodiment, and as shown in the view of FIG. 6, the transfer,opening, filling, top sealing and discharge are carried out throughvarying sectors or arcs of a circular pouch path or pitch line definedin part by the filler wheel. Thus, in one embodiment, pouch transfer tothe filler wheel occurs in a pouch transfer sector or arc of about 42degrees. Pouch opening occurs in a sector of about 36 degrees. Pouchfilling occurs in a sector of about 120 degrees, pouch closing andproduct settling occurs in a sector of about 61 degrees, hot air topsealing occurs in a sector of about 58 degrees, final roll crimping orsealing occurs in a sector of about 13 degrees and pouch dischargeoccurs in a sector of about 30 degrees. Filler wheel diameter and numberof pouch stations are provided to accommodate the times required forthese operations as the pouches move through the generally circularoperational path at the desired throughput speed, the time each pouchtraverses through an operational sector being sufficient for theeffective operation performed in that sector at the throughput speedsdesired, and for continuous operation. As an example, a filler wheelmight provide 24 to 32 pouch stations. Other numbers of stations may beprovided within these parameters.

Turning now to an alternative embodiment as shown in FIGS. 11-12, forexample, it will be appreciated that in this embodiment, the pouches arenot separated before they are filled, but rather are entrained about afiller wheel, filled, sealed and then cut off, one from another, as willbe described.

In this embodiment, it is of course still necessary to providetransverse seals in a folded web pouch and to this end, a verticalsealer 10 can be provided in a sealer module 11 as disclosed in FIG. 1with respect to the first embodiment described above. The verticalsealer 10 in the second embodiment shown in FIGS. 11-12 can be identicalto that described above with respect to the first embodiment.

In the embodiment shown in FIGS. 11-12, a pouch forming, filling andsealing operation 100 is illustrated. This operation typically includesa pouch web sealer forming transverse seals in folded webs of the pouch,just as described above. The pouch web is then introduced to a fillerwheel 106 carrying a plurality of seal supporting lands 101 mountable onwheel 106 and engaging the transverse seals between the pouches. Theselands are preferably spaced at a chord length slightly less than thewidth of the pouch so that the mouths 102 of the pouches can be heldopened as the pouches reside on the lands and as they are transported inthe direction of the arrow 103 for filling, as product is transferredthrough a plurality of spouts 104 on the spout wheel 105 rotationallydisposed above the filler wheel 106 carrying the lands 101.

Similarly to the prior embodiment, the spout wheel 105 is slightlytilted over the filler wheel 106 so that spouts can be positioneddirectly over the pouches with the lower discharge ends of the spouts inposition for filling the pouches as the spout wheel turns with thefiller wheel. After the pouches are filled, they are still disposed in apouch train and transported to a sealer 108 operable to seal the topmouths of the pouches together. Thereafter, the pouches are transportedthrough a crimping roller operation 110 and may be inverted to ahorizontal form through feed rollers 111 in direction of arrow 112 to aknife 114 where individual pouches P-1 are cut and discharged from theoperation.

The actual opening, filling, closing and sealing of the pouches asillustrated in FIG. 11 in this embodiment is similar to prior pouchtrain filling devices. It will be appreciated, however, thataccommodation is made in the filler area to handle pouches in a widerange. Features of a pouch width adjustable filler wheel 106 areillustrated in exploded form in FIG. 12.

In FIG. 12, there is shown a vacuum shoe or turret 116, the filler wheel106, and the spout wheel 105 carrying a plurality of spouts 104. Theturret 116, filler wheel 106 and spout wheel 105 are operablyinterconnected together in operation to perform the filling process.

It will be appreciated, however, that the lands 101 are provided in thefiller wheel 106 by means of respective mounting areas such as slots117, for example. In order to facilitate change of the filler operationfrom one size pouch to another, a plurality of filler wheels 106 can beprovided with heated lands 101. It will be appreciated that each fillerwheel 106 is provided with a plurality of vacuum passages 118interconnected with appropriately disposed vacuum passages in the heatedlands 101 for providing vacuum to the ports 119 in the heated lands 101.

Each of the vacuum passages 118 has a lower port 120 and each of theseports for the respective filler wheel 106 are located at a set radialdistance outwardly from the axis of rotation 122 of the filler wheel andspout wheel.

The vacuum turret 116 is provided with a plurality of vacuum ports andsets, such as vacuum ports 123 in one set, vacuum ports 124 in anotherset, and vacuum ports 125 in another set. Each of the sets of vacuumports 123, 124, 125 is disposed at a different radial distance from thecenter axis 122 of the turret 116.

Accordingly, when the filler wheel 106 is disposed on the vacuum turretor shoe 116, and rotated, the ports 120 of the filler wheel areoperatively associated with the ports at 123 on the vacuum shoe as thefiller wheel 106 is turned. When the filler wheel 106 is changed out foranother filler wheel which, for example, has vacuum lands 101 set at adifferent radial distance from the axis 122, that filler wheel has a setof ports which communicates with port set 124 or 125, for example, inthe vacuum shoe 116. By this means, the filler can be changed out tohandle different pouch sizes by simply providing a plurality of fillerwheels 106, each with a set of vacuum lands, but the vacuum lands havingouter surfaces spaced at different radial distances from the center 122so that the chords or distances between the effective surfaces of thevacuum lands on the different filler wheels are positioned to handle aparticular pouch width.

Accordingly, it will be appreciated that a variety of change outstructures can be provided in this embodiment. For example, a pluralityof filler wheels, each with a set of lands spaced at different radialdistances than the lands of other filler wheels could be provided.

Alternately, a single donut-shaped ring or wheel, such as illustrated at106 in FIG. 12, could be provided, and a plurality of vacuum lands couldbe adjusted in a radial direction within slots 117 to extend atdifferent radial distances from the donut or wheel 106, thereby onlyrequiring a single set of vacuum lands, each with its own vacuum ports,for interacting with the specific vacuum port sets of the vacuum turret116 determined by radial adjustment of the lands. Further, varied setsof vacuum lands could be removably mounted on a single donut or ring toprovide changeout.

In this regard, on change out, the spout wheel 105 carries a pluralityof changeable spouts 104 which can be snapped in or out, depending onthe particular spout configuration needed to handle the particular pouchwidth selected. Alternately, a plurality of spout plates, each with itsown set of spouts, could be provided for cooperating with the particularfiller wheel selected for the pouch width to be filled.

Once the pouches are filled and sealed as shown in FIG. 11, they aretransported to the knife 114 for cutting the pouches. In the past, pouchcut off knives have been provided with slight degrees of adjustability,so that the package guides associated with the knives can be adjustedradially inwardly and outwardly to accommodate slight variations in theseal to seal distances defining each of the filled pouches. Theadjustments provided as noted above have been accomplished in the pastby means of screw operated cones maneuvering pouch guide mountingstructures. Change out of knife hubs of different sizes requires changein the distance between the otherwise fixed axes on which the major andminor hubs rotate and is thus a problem.

In this embodiment, it is desired to provide an improved knife withplural hub sets which can be changed out to handle pouches in differentwidths by the mechanism of simply changing the major and minor knifehubs. Two or more knife hub sets can be provided to handle pouches ofvarying width or at varying pitch from one operation to another with asimple hub set change from one hub set to another. This is accomplishedby a four gear drive train described below which accommodates variationin the space or distance between major and minor hub drive axes requiresfor hub set change. Such an overall knife 114 according to the inventionis shown in FIGS. 13 and 14 and additional features thereof in FIGS. 15and 16.

FIGS. 13 and 14 show the knife 114 from opposite sides. The knife maycomprise a knife module defined, in part, by two mounting plates 128 and130. A minor knife hub 131 and a major knife hub 132 are mountableoutside the plate 128 on respective bearings. For example, the major hub132 is mounted on a major hub drive axis 133, while the minor knife hub131 is mounted on a minor hub drive axis 134. Major knife hub 132 ispreferably mounted on fixed bearings in the plates 128, 130. On theother hand, minor knife hub 131 is mounted on an axis journaled inmovable bearings. For example, a bearing is disposed in a bell housing136 which can be adjusted by means of the wheel 137 having a shaft 138attached to the bell housing 136.

When the bell housing, which can be belted to plate 128, is loosened,rotation of the wheel 137 in shaft 138 can move the bell housing 136 ina vertical direction, such as shown by the arrows 139, 140. Similarprovisions can be made to loosen the bearing journal for the minor knifehub shaft in plate 130, if such journal is desired. Thus, the minor hubdrive shaft can be moved toward or away from the major hub drive shaftto accommodate hub set change.

It will be appreciated that, upon change out for different pouch websizes, different major and minor knife hubs are changed out and providedon the axes 133 and 134, respectively. In this regard, it will beappreciated that the effective cutting diameters of the cooperatingknife hub sets are different.

The differences in diameters of the respective knife hub sets used onchange out will, by necessity, vary the distance D between the driveaxes 133 and 134 by the above described structure. In order toaccommodate differential positions of the axis 134 with respect to thefixed axis 133, the drive must also be variable as relative movement ofthe drive axes 133, 134 requires a resulting accommodation of the drive.There is thus provided according to the invention a four gear anti-lashgear drive train 142 as best seen in FIG. 13, and showing four gears ina gear linkage comprising the four gear drive train.

Accordingly, it will be appreciated that a first drive gear 143 issecured to the major knife hub shaft 144 for rotating the knife hub 132,such as through a belt 145 driven by a drive pulley 146.

It will also be appreciated that a slave gear 147 is secured to thedrive shaft 148 for the minor knife hub 131 on axis 134. A firstanti-lash gear 149 is mounted on a fixed axis 150, about which a pivotarm 151 is also mounted. A second anti-lash gear 152 is rotationallypivoted to the arm 151. The axis of the gear 152 and thus movable gear152 can be moved circumferentially around the fixed axis 150, movablegear 152 accommodating changes in the spacing of axes 133, 134.

An adjustment arm or actuator 154 is attached between the top of pivotarm 151 and plate 130, for example, so that when the pivot arm isloosened, the adjustment arm 154 can be rotated or operated to adjustthe angular disposition of the pivot arm 151 about the axis 150.

It will be appreciated that when the pivot arm is moved away from theaxis 134, for example, in the direction to the left of the arrow 156,the one anti-lash gear 152 is moved away from but is re-engageable withthe slave gear 147. This allows the slave gear to be moved upwardly anddownwardly as the shaft 148 is moved upwardly and downwardly uponrotation of the wheel 137 and movement of the bell housing 136, or inother words, as the distance D between axes 133, 134 is changed toaccommodate substitution of one hub set for another.

Once the major and minor knife hubs are changed out, the bell housing ispositioned for appropriate interaction and cooperation between the minorand major knife hubs and the bell housing and any bearing journals forthe shaft 148 are fixed. Thereafter, the adjustment arm 154 is operatedto move the pivot arm in the opposite direction of the arrow 156 tore-engage the anti-lash gear 152 with the slave gear 147 andre-establish an effective drive train and rotational drive between thedrive gear 143 and the slave gear 147. Thus, gear 152 is moved fordisengaging, then re-engaging gear 147.

In this way, variations in the effective operational diameters of theminor and major knife hubs and the changes in the distance D between theaxes 133 and 134 resulting therefrom are accommodated.

From the illustrations in FIGS. 13 and 14, it will be appreciated thatthe major knife hubs 132 include a plurality of extendible packageguides 160 with fixed shear edges, which cooperate with the extendingknife edges or blades 161 of the minor knife hub 131, so that as the twohubs are respectively rotated, the filled pouch web extendingtherebetween are cut off, one pouch from the other, in the sealerbetween the pouches.

As in the past, vacuum cups 163 are provided to hold the pouches on theknife until they are discharged, generally at the bottom of the majorknife hubs 132.

According to the invention, the package guides can be adjusted toaccommodate slight variations in the positioning of the web sealsbetween the filled pouches. Such an improved mechanism is illustrated inFIGS. 15 and 16. The package guides 160 are each mounted on aselectively reciprocating package guide support arm 166. Each supportarm 166 is reciprocally mounted and has, at its bottom end, a beveledpinion gear 167 mounted for rotation on the knife structure, such as inbrackets 168 as shown in FIG. 16, so that rotation of the gear 167selectively drives and extends or retracts the guide.

A beveled ring gear 169 is applied in meshing engagement to the beveledpinion gears 167 such as, for example, to the exposed portions of thosegears shown in FIG. 15. Beveled ring gear 169 can be phased with respectto the extendible package guide supports so that relative rotationbetween the ring gear 169 with respect to the brackets 168 serve to turnthe beveled pinion gears 167. That turning of those beveled pinion gears167 extends or retracts the arms 166 in the direction of arrows 170 inorder to adjust the extension and retraction of the package guides 160.Thus, the guides are extendible responsive to rotation of the gears 167,169.

This variation or adjustment can be used to change the chord lengthsbetween the package guides to accommodate slight variations of sealerorientation in the pouch web which is being cut.

Accordingly, by change out of major and minor knife hubs at varyingoperable diameters to accommodate a wide range of pouches, and byprovision of easily adjustable package guides 160, a wide range ofpouches can be handled in the knife, including pouches having widthsranging from 2.5 to 5.5 inches, for example.

The invention also contemplates three other alternative embodiments aswill now be described.

In one embodiment, shown in FIG. 18, the discharge wheel 28 is deletedand a pinch belt discharge module or structure 200 is substituted. Inthis embodiment, the pouch web is formed by any suitable means and thepouches are cut, filled and sealed as described with respect to FIGS.1-10. After sealing and any top or mouth crimping, the pouches areretained on filler wheel 18 within their path of travel defined by apitch line of circular or curved orientation until they reach a pouchdischarge sector illustrated in FIG. 6. As the pouches enter thissector, they are held by the gripper units used at their leading andtrailing side seams and just below the sealed top edges or top portionof the pouch.

The pinch belt structure 200 includes two opposed pinch belts 201, 202defining a pouch oriented in part in a curved orientation. The beltsprovide between them a pouch top pinch run 204 defined by a set ofroller guides 203. This run is aligned with and preferably has an entryportion tangent to the curved pouch pitch line in which pouches aretransported on filler wheel 18.

As the separate pouches P approach the pinch run 204, the leading end ofupper edge or edges of the pouch top is engaged by the two opposed belts201, 202 and the clamping components of the leading gripper jaw (belowthe pouch top) are opened to release the leading pouch edge from thegripper unit used, and the wheel 18, thus introducing it to thedischarge module 200. Continued forward motion of the pouch results inmore of the pouch top portion being captured between the belts 201, 202.The clamping components of the trailing jaw of the gripper is openedthen, sequentially to that of the leading jaw, to release the trailingedge of the pouch top portion to the pinch belts.

From there, the pouches P are discharged in the direction MD-1 forfurther handling or packaging. As well, the trailing gripper jaw ismoved by a cam to a proper position relative to its associated leadingjaw for picking up the trailing edge of a new, empty pouch from theknife 12 in the pouch transfer sector.

In another aspect of the invention, illustrated in FIG. 19, a sealer 210comprises hot air or electrical sealing platens 211, 212 disposedoperationally on opposite sides of pitch line P2 (FIG. 19). Theseplatens are movably carried by any appropriate frame structure mountedfor vertical and horizontal or lateral movement, such as by air orhydraulic cylinders, or electric solenoids. Accordingly, platens 211,212 can be moved vertically upwardly from pitch line P2 to clear anypouch material, then horizontally or laterally and then downwardly, allas shown by arrow B, to space the heated platens from the pouches. Thisprevents undue heat propagation into the pouch material or cycle oremergency or other stops. Any suitable framework and mover componentscan be utilized to so move the platens and they can be mounted to moverespectively to each other for clearing, then repositioningoperationally on startup with respect to the pouches at the sealingstations.

Such a sealer 210 can be used with any of the embodiments describedherein.

In yet another aspect of the invention, an alternative drive apparatusis contemplated. For given ranges of pouch sizes, this alternative drivecan provide for pouch width accommodation without the need to change outany spout wheel or the spouts thereon.

Such an embodiment is shown in FIG. 20 and contemplates the use ofseparate servo drives for each of the filler wheels 18 and 181 on onehand and the spout plates 20 on the other hand. In this regard, a fillerwheel 18 or wheel 181 is carried on a hub 220 provided with a drive ringor gear 221 engageable by a drive pinion 222 on a drive shaft driven bya first servo drive 223.

Spout wheel 20 is connected to a rotatable drive shaft 230 extendingthrough hub 220. Shaft 230 is driven by a separate and independentsecond servo drive 231 and is rotatable independently of hub 220. Spoutplate 20 and filler wheel 181 are thus independently driven by separateservo drives, independent of each other.

Servo drives 223, 231 are electrically controlled so that spout wheel 20and filler wheel 18 or 181 can be driven at the same speed, but also canbe adjusted in rotational phase with respect to each other toaccommodate variations of pouch width.

In this regard, it will be appreciated that the pouches are held onwheel 18 by gripper units having leading and trailing jaws. Lead jawsare fixed in circumferential position on wheel 18 or 181 while thetrailing jaws are movable with respect to the leading jaws.

Accordingly, the position of the center of one pouch on thecircumference and pitch line between its leading and trailing edge isdifferent from the position of the center on the circumferential orpitch line of another pouch of varied size. For example, the verticalcenter line of a narrower pouch is closer to its leading edge, fixed onthe wheel 18 or 181, than is the vertical center line of a wider pouchwhich is slightly retarded along the pitch line.

Optimally, it is desirable to align the bottom discharge port of a spoutwith the center line of the pouch. Accordingly, by adjusting the phaseof the spout plate 20 with respect to the filler wheel 18 or 181 whenpouch widths change, then running them at the same speed, the spouts aremoved to proper alignment with pouches within the design range of pouchwidths. The same spouts are sized and configured to discharge productinto pouches throughout the pouch width range.

Change out for different pouch sizes is thus accommodated by a simplephase adjustment, accomplished through independent servo control,without requiring spout wheel or spout changeover to additional parts.

Such independent servo drives may also be applied to the fillerembodiment of FIGS. 11-12, for example, where a phase adjustment asdescribed may render change parts unnecessary for desired pouch widthchanges.

Accordingly, the invention contemplates several embodiments andvariations for accommodating forming, filling and sealing pouches in awide range of pouch widths, particularly including but not limited to2.5 to 5.5 inches wide, and at relatively high pouch speeds through thesystem of up to approximately 500 pouches per minute. Change out forpouch size variation within a design range is facilitated with either nocharge parts or minimal change parts as described.

While the embodiments disclosed have one application for a wide range ofpouch widths, such as 2.5 inches to 5.5 inches, the invention can besized to handle pouches of even larger widths such as 6, 8 or 10 inchesor even larger, with size changes to the components described asnecessary with the desired pouch size, and with a variety of ranges ofsuch larger pouch sizes.

Also, the various modules described herein can be used in variousconfigurations, or independently of the other. For example, the verticalsealer module 11 could be utilized to provide a transversely sealedmultiple pouch web with open top pouches in sequential train for avariety of fillers, or for stock storage. The filler module 19 and thefiller of FIG. 11 could be used independently of the vertical sealermodule 11. The knife module 13 of FIG. 1 could be separated from thefiller module 19, with cut pouches being stored, provided to a pouchmagazine, or fed by other means to a filler handling cut-off, as opposedto entrained, pouches. The knife embodiments 114 of FIG. 11 and of FIGS.13-16 can be used with filling and sealing apparatus or modules asdescribed herein or with other filling or sealing apparatus.

Finally, it will be appreciated that the gripper units described hereinare mounted on, mounted directly to, or are carried by the filler wheel,as opposed to being mounted on, mounted to or carried by chains in apath for filling.

It will be appreciated that combinations of the embodiments, elementsand

1. An adjustable pouch machine comprising: a vertical sealer for forming transverse seals between two plies of a pouch web to partially define a plurality of pouches in said web, and including a vertically oriented sealer wheel rotatable on a substantially horizontal axis; and a filler wheel having a plurality of adjustable gripper units mounted thereon for transporting independent separate pouches cut from said pouch web about a circular path, defined in part by said filler wheel, for filling.
 2. A machine as in claim 1 wherein the vertical sealer includes pouch web entry and exit rollers at least one movable toward and away from the other to respectively tension said pouch web when against heated lands on said vertically oriented sealer wheel and to selectively relax tension of said pouch web with respect to said lands.
 3. A machine as in claim 2 wherein said vertically oriented sealer wheel includes a plurality of heated lands on said wheel, said lands being adjustable radially on said vertically oriented sealer wheel.
 4. A machine as in claim 2 wherein at least one of said entry or exit rollers are movable to relax tension of said pouch web sufficiently to move away from said lands.
 5. A machine as in claim 2 wherein said entry or exit rollers are movable between positions sufficiently distant from each other to relax tension in said pouch web when said vertically oriented sealer wheel is stationary.
 6. A machine as in claim 1 further including a tilted spout wheel disposed over said filler wheel and including pouch top seal apparatus oriented between said tilted spout wheel and said filler wheel
 7. 7. A machine as in claim 6 including a plurality of removable spouts mounted on said tilted spout wheel.
 8. A machine as in claim 1 further including a discharge wheel mounted proximate said filler wheel and having a plurality of pivoted arms for transferring vertically oriented pouches from gripper units on said filler wheel to horizontal orientation for discharge.
 9. A machine as in claim 1 wherein said gripper units include leading and trailing jaws at least one movable with respect to the other to accommodate a wide range of pouch widths.
 10. A machine as in claim 9 wherein a trailing jaw is connected to a parallel link to maintain said trailing jaw parallel to a leading jaw.
 11. A machine as in claim 1 wherein said gripper units include pouch engaging leading and trailing jaws, said trailing jaw being shiftably mounted on said filler wheel to accommodate pouches of various widths.
 12. A machine as in claim 1 wherein said gripper units include a pouch engaging trailing jaw mounted on an arm pivotally mounted on an axis perpendicular to said filler wheel.
 13. A machine as in claim 1 further including a knife disposed proximate said filler wheel for cutting separate pouches from said pouch web for transfer to said filler wheel.
 14. An adjustable pouch sealing and filling machine comprising: a vertical sealer for forming transverse seals between two plies of a pouch web and including a vertical sealer wheel; a filler wheel comprising one of a plurality of filler wheels for selectively operably coupling to said sealing and filling machine, said plurality of filler wheels having vacuum lands mountable thereon at effectively different radial positions than vacuum lands on others of said plurality of filler wheels to accommodate pouches in a wide range of widths dependent on the filler wheel operably coupled to said sealing and filling machine.
 15. A machine as in claim 14 wherein each of said plurality of filler wheels include vacuum lands providing different effective land diameters on one filler wheel varying from the effective land diameters of other filler wheels in said plurality.
 16. An adjustable pouch filler wheel for a pouch machine including an annulus, a set of vacuum lands on said filler wheel for engaging seals between pouches in a pouch web entrained on said annulus, and the radial position of said vacuum lands on said filler wheel being adjustable to accommodate a wide range of pouch widths.
 17. A filler wheel as in claim 16 including a vacuum turret having a plurality of vacuum ports operably connected to provide vacuum to said lands throughout the radial extension of said lands.
 18. An adjustable pouch filler including a filler wheel and a plurality of vacuum lands movable on said filler wheel to varied radial positions on said wheel.
 19. A filler wheel as in claim 18 including a vacuum turret having a plurality of vacuum ports operably connected to provide vacuum to said lands throughout the radial position of said vacuum lands on said wheel.
 20. A knife for cutting filled and sealed pouches from a web train of filled and sealed pouches, and including at least two knife hub sets each knife hub set including a major and a minor knife hub, respectively mountable on respective major and minor hub drive axes, and a four gear drive train having four gears, including a movable gear accommodating changes in the distance between said hub drive axes when one hub set is changed for another.
 21. A knife as in claim 20 wherein at least one of the four gears of the four gear drive train is selectively removable from engagement with a gear driving one of said hubs to accommodate change in the distance between said hub drive axes and is re-engageable to provide an effective drive train upon changing of said hub set.
 22. A knife as in claim 20 including radially adjustable package guides on one of said hubs, said package guides mounted on respective reciprocable arms having a beveled gear mounted on each of said arms, and a ring gear mounted for rotational adjustment, said ring gear meshing with said beveled gears for turning said beveled gears to adjust the radial extension of the package guides by reciprocating the arms responsive to rotation of said ring gear and said beveled gears.
 23. A vertical sealer for forming transverse seals in a multiple ply web, said vertical sealer comprising: a vertical sealer wheel; a plurality of sealer lands on said wheel; and web handling apparatus for selectively tensioning and relaxing tension of said multiple ply web with respect to said sealer lands.
 24. A vertical sealer as in claim 23 wherein said vertical sealer wheel is oriented for rotation about a substantially horizontal axis.
 25. A vertical sealer as in claim 24 wherein said web handling apparatus comprises web-engaging rollers mounted for respective movement in oblique respective directions with respect to said vertical sealer wheel.
 26. A vertical sealer as in claim 25 wherein said rollers in one position produce tension in said multiple ply web, urging said multiple ply web against said sealer lands, and in another position relaxing said tension sufficiently to space said multiple ply web from said sealer lands.
 27. A vertical sealer as in claim 26 wherein said rollers are respectively mounted on an extensible and retractable support.
 28. A vertical sealer as in claim 23 wherein said handling apparatus comprises multiple ply web entry and multiple ply web exit rollers mounted for movement between positions in directions extending obliquely to said vertical sealer wheel.
 29. Apparatus for handling filled and sealed pouches and comprising a discharge apparatus having two opposed belts defining a pouch engaging path between said belts.
 29. Apparatus as in claim 28 wherein said discharge apparatus is combined with a pouch filler defining a pouch pitch line along which pouches are moved, said pouch engaging path being aligned with said pouch pitch line in a transfer area between said filler and said discharge apparatus.
 30. Apparatus as in claim 29 wherein said pouch engaging path is curved.
 31. Apparatus as in claim 30 wherein said pitch line has a curved orientation and said pouch engaging path has an entry portion tangent to said pitch line.
 32. Apparatus as in claim 29 wherein said pouch filler includes pouch grippers oriented and operable to engage pouches at positions below top portions thereof, and wherein said pouch engaging path is oriented to engage top portions of said pouches above said positions below said top portions.
 33. Apparatus for filling and sealing pouches and including a spout wheel and a filler wheel for supporting pouches to be filled through spouts carried on said spout wheel, the improvement comprising the combination of: a first servo drive for driving said filler wheel; a second servo drive for driving said spout wheel; said first and second servo drives respectively driving said respective filler and spout wheels independently of each other; and at least one of said first and second servo drives being controllable to adjust a phase of rotation between said filler wheel and said spout wheel.
 34. Apparatus as in claim 3 wherein said filler wheel is mounted on a hub driven by said first servo drive.
 35. Apparatus as in claim 34 wherein said spout wheel is mounted on a drive shaft driven by said second servo drive, said drive shaft extending through said hub to said spout wheel.
 36. Apparatus as in claim 34 including a ring gear operably connected to said hub and a drive pinion engageable with said ring gear and driven by said first servo drive.
 37. Apparatus for filling and sealing pouches and including a top pouch mouth sealer comprising sealing platens disposed on each side of a pouch pitch line through which pouches are transported, said sealing platens being movable away from said pitch line to prevent heat propagation into said pouches.
 38. Apparatus as in claim 37 wherein said sealing platens are movable upwardly and laterally away from said pitch line.
 39. Apparatus as in claim 38 wherein said sealing platens are movably mounted in a direction away from said pitch line upon cycle stop, emergency stop or other stop of said apparatus.
 40. A pouch filler comprising: a filler wheel, a plurality of pouch gripper units for receiving and holding a pouch for filling, said gripper units including leading and trailing jaws mounted directly on said wheel for rotation by said filler wheel.
 40. A pouch filler as in claim 40 where in at least one of said jaws is pivoted to said filler wheel.
 41. A pouch filler as in claim 41 wherein said at least one jaw is pivoted to said filler wheel about a vertical pivot axis.
 42. A pouch filler as in claim 42 wherein said at least one jaw has a pouch clamping member for clamping a portion of a pouch, said clamping member pivotably mounted to said filler wheel about a vertical pivot axis.
 43. A pouch filler comprising: a filler wheel; a plurality of gripper units mounted on said wheel said gripper units including leading and trailing jaws, one movable about a horizontal axis selectively toward and away from the other, each of said jaws having a pivoted clamping member rotatable about a first vertical axis for selectively clamping and releasing a portion of a pouch.
 44. A pouch filler as in claim 44 wherein said filler wheel rotates about a second vertical axis and wherein said first and second vertical axes are parallel to each other and one perpendicular to said horizontal axis.
 45. A pouch filler comprising: a filler wheel, a plurality of gripper units mounted on said wheel, said gripper units including leading and trailing jaws, one movable about a first vertical axis selectively toward and away from the other, each of said jaws having a pivoted clamping member rotatable about a second vertical axis for selectively clamping and releasing a portion of a pouch.
 47. A pouch filler as in claim 46 wherein said filler wheel is rotatable about a third vertical axis and wherein said first vertical axis, said second vertical axis and said third vertical axis are parallel to each other.
 48. In a pouch forming and filling apparatus, a plurality of modules including: a vertical sealer pouch forming module for providing transverse seals in a folded web; a knife module for cutting individual pouches from said web; a filler wheel module having a filler wheel for receiving individual pouches in respective gripper units directly mounted on said filler wheel; and said modules being selectively and operably combined for forming, filling and sealing pouches.
 49. A method of forming pouches from a web of pouch material including the steps of: engaging two plies of pouch material in said web against sealing lands mounted on a vertical sealer wheel rotating on a substantially horizontal axis to seal said plies together; and selectively relaxing tension on said plies sufficiently to cause said plies to disengage from contact with said sealing lands.
 50. A method as in claim 49 including the preliminary step of folding a pouch web and engaging said folded web on said sealing lands for forming transverse seals across said folded web in adjacent plies thereof.
 51. A method as in claim 50 including the step of tensioning a folded pouch web, to engage said sealing lands, between folded pouch web entry and folded pouch web exit rollers oriented adjacent said vertical sealer wheel at a distance apart less than the diameter of said wheel.
 52. A method as in claim 51 including moving said rollers apart and relaxing tension in said folded pouch web to disengage said web from said sealing lands.
 53. A method as in claim 49 including selectively moving said sealing lands in a radial direction to produce transverse seals in said plies at selected spacing apart from one another.
 54. A method of filling pouches comprising the steps of: feeding separate pouches toward a generally horizontal filler wheel, engaging leading and trailing edges of said pouches with respective leading and trailing jaws carried on said horizontal filler wheel; and selectively pivoting said trailing jaw on an axis generally perpendicular to said horizontal filler wheel to accommodate pouches of varied widths.
 55. A method as in claim 54 including transporting filled pouches through a top sealer and selectively moving said top sealer away from said pouches when said filler wheel stops.
 56. A method as in claim 55 including engaging upper edges of sealed pouches above a position where said pouches are engaged by said jaws for releasing pouches from said jaws and moving pouches away from said filler wheel.
 57. A method as in claim 56 including sequentially releasing a leading jaw then a trailing jaw from a pouch as its upper edge is engaged.
 58. A method as in claim 54 including discharging pouches from said horizontal filler wheel and orienting discharging pouches horizontally.
 59. A method of filling transversely sealed pouches in a train of pouches including the steps of: engaging and supporting transverse seals in said train on vacuum lands carried on a first wheel; and selectively substituting for said first wheel a second wheel having vacuum lands at a different radial position on said second wheel than the radial position of vacuum lands on said first wheel.
 60. A method of filling transversely sealed pouches in a train of pouches including the steps of: engaging and supporting transversely spaced seals between pouches on radially adjustable vacuum lands; and selectively radially adjusting said radially adjustable vacuum lands for other pouch trains where said transversely spaced seals are spaced at another distance apart than the distance between transversely spaced seals of one pouch train.
 61. A method of cutting transversely sealed pouches from respective pouch trains along transversely spaced seals partially defining said pouches and wherein the distance of spacing between said transversely spaced seals in respective pouch trains varies, the method including the steps of: driving major and minor knife hubs respectively disposed on major and minor axes at least one selectively movable with respect to the other, to cut along transversely spaced seals of pouches of one train between said hubs; driving one of said hubs through a gear linkage, having a plurality of gears with another of said hubs; changing said hubs to accommodate cutting pouches from pouch trains having different transversely spaced seal spacing; and during said changing, disengaging at least one of said gears from said gear linkage and re-engaging said one gear in said gear linkage after changing said hubs to accommodate a variation of distance between said major and minor axes.
 62. A method as in claim 61 further including the steps of engaging transversely spaced seals in a pouch train on package guides mounted on radially extendible package guide supports driven by pinion gears and selectively rotating a drive ring engaging said pinion gears to radially extend and retract said package guides for handling respective pouch trains having transversely spaced seals at different spacing.
 63. A method of handling filled, sealed and separate pouches carried between leading and trailing jaws, including the steps of: introducing a top portion of the leading edge of a pouch between two opposed belts; releasing a leading jaw from a leading edge of the pouch; transporting said pouch between said belts; and thereafter releasing a trailing jaw from a trailing edge of said pouch.
 64. A method of filling pouches including: supporting pouches for filling on a filler wheel; filling pouches carried by said filler wheel through spouts disposed on a spout wheel above the filler wheel; driving said filler wheel by a first servo drive; driving said spout wheel by a second servo drive; and independently adjusting a rotational position of one of said filler wheel or said spout wheel with respect to a rotational position of the other of said filler wheel or said spout wheel by operating at least one of said first or second servo drives independently of the other to thereby adjust the rotational phase of said filler wheel and spout wheel with respect to each other and thereby accommodate filling pouches of varied width carried by said filler wheel. 